Dana 300 popping out of gear...

rockcity

rockcity

everyday is a chance to get better
Joined
Apr 10, 2005
Location
Greenville, NC
I have a Dana 300 that seems to sometimes pop out of gear under load. Really, I've only noticed it in 4wd Low and when traversing a steep downhill and using the gearing to control the speed of the vehicle. It seems to pop out of gear.

I have twin sticks, Lowmax 4:1 and the 32 spline outputs front and rear. I picked up the case used but haven't heard back from the previous owner about it.

Any ideas where to start? I've never had issues with any of my Dana 300s I've had in the past. I haven't adjusted the shifter cables (NW fab) but I wouldn't think that would affect it coming out of gear. The shifter levers are not bottoming out and it seems to fully shift into the selected gear.


Help.
 
Put some kind of spring/bungee cord/tension device on the shifter to keep it in gear. Seems to be a common problem. Lots of talk about this on Pirate in the gen4x4 section these days.
 
when I physically hold the shifter in place, it still pops out. I can easily shift it back in gear, but it pops out even with physical pressure from me trying to keep it in gear
 
Ive got the same issue, and have had it from 3 cases now. I keep hearing about changing the ball detent spring on the shift rod, but if you cant hold it in gear that aint gonna help. will it stay with the front and rear both in low? mine will, but kicks out if just the rear is in.
 
Everyone I can think of that has/had a 300 or a stak has the same issue. Its never really bothered me, one extension of the arm and its all good.
 
Sounds to me like there is a problem in the shift rails. Possibly a bad spring? I suggest pull and dissasemble the case, or at least take the drain pan off and look inside at the gears. Shift through all gears, and check to see is the shift rail is fully engaged on all gear sets. Could be the gear assemblies need to be spaced either which way too.
 
I have the same problem on mine, and I've just gotten used to it. It doesn't actually come out of gear, but it pops out and back in on its own. Really annoys me and I swear I will fix it eventually, but I haven't determined how yet.
 
GubNi said:
There's a special spring kit to fix that. The problem is it makes it really hard to shift.
Click to expand...
I put in the stiffer springs and also cut off the head of a sheet metal screw and dropped it in the deepest hole for the spring to sit on. It does make it hard to shift, but it doesnt pop out of gear anymore.
 
I don't see why adjusting the shifter cables will have any help on the issue. There is plenty of room for them to shift past where they are when in 4Low. I would think adjusting the cables will just adjust the location of the levers only...
 
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